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S t r u c t u ra l P r o d u c t s

CI/SfB (28) Hh2 February 2007

Composite Slab Flooring System


Using DRAMIX Steel Fibre Concrete - Projects Book

Building to the Power of

Kingspan and Bekaert Composite Slab


No Mesh Construction
Dramix Steel Fibre Concrete, has been used throughout Europe in Industrial Floors and External Pavements for many years. Following extensive test work and analysis by The Steel Construction Institute it is now available for multi-storey applications. Dramix steel fibres with Multideck profiles have been proven by testing to achieve full fire performance for 1 - 1.5 hours. The use of a Dramix Steel Fibre reinforced Concrete slab provides a pre-reinforced concrete slab - no mesh has to be installed.

Is it more difficult to pump?


No. The fibres spread evenly during the mix. Pumping to heights is no problem using normal pumping equipment.

How does it lay?


Dramix lays perfectly. And, of course, theres no mesh to trip over - eliminating a site safety hazard.

So who is using it?


Dramix has been used on many projects in different sectors such as the Colmore Plaza on all of its 14 floors, 10 storey Teesside House in Middlesbrough. Thanet Retail Park, Spurriergate in York mixed development and the prestigious Quebec Buildings Residential Development in Salford Manchester.

great step forward in composite floor construction


Are You Still Quoting For Mesh?
Mesh is hassle. You have to buy it, transport it, store it, crane it, and fix it. Its tricky to work on AND it costs good money. If youre still using mesh youve probably not heard of Dramix steel fibres.

Why are Kingspan promoting the product?


We believe this is a great step forward in composite floor construction for multi-storeys. So weve spent considerable time and resources testing Dramix and Multideck. The combination is the first design with a proven 1-hour and 1.5 hour fire rating.

Where can I get more information?


For literature & technical advice on the Dramix product contact Bekaert on 01142 427 485 or email bill.thomson@bekaert.com

So what is Dramix?
Dramix fibres are steel wire filaments with hooked ends manufactured by Bekaert Ltd. They are added to the concrete mix to provide a pre-reinforced concrete suitable for pumping straight on to the metal deck.

And its as good as mesh?


Yes, The fibres provide full depth reinforcement and excellent crack control. Whats more the design is endorsed by the Steel Construction Institute (SCI).

1. Steel fibres added to hopper

2. Fibres mix perfectly with concrete

3. Concrete pumped into position

4. Mixture spread onto deck

Construction Advantages
Pre-Reinforced Concrete Simplified process No mesh to transport,

buy, store, lay etc...


Time savings on site Earlier project completion Concrete volume savings Reduction in crane hire time

Technical Advantages
Proven 1 hour & 1.5 hour fire rating Structural design information

developed by SCI
Full depth reinforcement offers

excellent crack control


Design advice and assistance

Health & Safety Advantages


Minimises site handling Reduces site congestion Minimises crane lifts Eliminates hand carrying

of mesh into position


Reduces tripping hazards

5. No mesh means no tripping hazard

6. Mixture floated off

7. Floating provides a smooth finish

8. Floor completed in double quick time

Hi-Rise

Colmore Plaza
Birmingham
Project Name Colmore Plaza Location Birmingham Structural Consultant Brookbanks Consulting Main Contractor Bowmer & Kirkland Ltd. Sub Contractors MSW, Twintec Usage Offices

The 155million Colmore Plaza project in Birmingham is the tallest building in the UK to specify Dramix Steel Fibre Concrete for each of its 14 floors. The Plazas city centre location necessitated carefully planned night pours of the innovative flooring solution. Space at the site is so restricted that a traditional mesh-based flooring solution was fraught with problems but Dramix pumped onto Kingspan Multideck was the easier and more economical answer. Dramix steel fibre reinforced concrete provides a pre-reinforced concrete slab which requires no mesh and simplifies the

floor laying process significantly reducing completion time and improving health and safety onsite. Dramix fibres are made from prime quality hard-drawn steelwire to guarantee high tensile strength and close tolerances. Added to the concrete mix, the fibres ensure full depth reinforcement and excellent crack control. For the Colmore building, Kingspan approved installer MSW laid the Multideck, whilst Twintec co-ordinated the addition of the steel fibres at a Cemex batching plant. The reinforced concrete was then pumped into each floor of the office building according to a strictly controlled night-time

schedule to cause minimum disruption to the surrounding area. When used in conjunction with Kingspan Multideck MD60-V2, Dramix Steel Fibre Concrete provides a proven 1 hour and 1.5 hour fire rating. Not only does mesh become redundant, but the shear resistance of Dramix concrete exceeds that of its mesh reinforced equivalent. In addition, the unique design of Kingspan Multideck reduces the volume of concrete required, bringing cost as well as time savings to a project. Dramix is now being specified in a number of key projects across the UK most notably where access or architectural conservation are significant issues. The solution, a joint initiative between Kingspan and Bekaert, has been tested by the Steel Construction Institute (SCI) and endorsed for multi-storey applications.

tallest building in the UK to specify Dramix Steel Fibre Concrete

Hi-Rise

Teesside House
Middlesbrough
The 3,160,000 project Teesside House in Middlesbrough is a 10 Storey scheme to provide a 388 bed student accommodation block in Middlesbrough town centre, with retail units and a restaurant on the ground floor. Due to the very limited access on the side roads on this town centre development the option to use fibres was put forward by Metaldeck, so as to remove the placement of large sheets of mesh reinforcement onto the 10 floors which would have been very problematic. The Mandale Group accepted the argument, and were persuaded by the savings in both time and money, not to mention the health and safety issues, by removing mesh from the scheme and replacing it with steel fibre reinforced concrete. The placing of the concrete took place in the first quarter of 2006, making it at the time the tallest building to have steel fibre concrete pumped onto its floors right up to 10 storeys
Project Name Teesside House Location Middlesbrough Structural Consultant Billinghurst George & Partners Main Contractor The Mandale Group Sub Contractors Metaldeck Ltd., Sidlow Brothers Ltd. Usage Student Accommodation/Retail

savings in both time


and money

Carrmills, Leeds

Leisure

Kirkby Leisure Centre


Liverpool
The 9,000,000 scheme is a new leisure centre comprising of a 4 court sports hall, 6-lane 25m pool, 12m by 10m learner pool, health and fitness/dance facility, shapers plus fitness room, multi purpose hall, wet and dry changing rooms, boxing club facility, aerobics studio, admin office, reception area, 6-lane athletics track, 2 artificial turf soccer pitches, landscaping and parking. Time savings and Health and Safety issues of using mesh were taken into account by the main contractor and the client in their decision to use a steel fibre reinforced concrete solution for the first floor, even though in this case access was not a problem!
Project Name Kirkby Leisure Centre Location Liverpool Architect and Engineer Knowsley Metropolitan Borough Council Main Contractor Shepherd Construction Ltd. Sub Contractors Metaldeck Ltd., Sidlow Brothers Ltd. Usage Leisure

savings time steel with fibre reinforced concrete


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Mixed Use

Express Networks
Manchester
The 8,000,000 scheme comprises office and shop units on the ground floor and first floor with 56 apartments over 6 storeys above. 28 parking spaces are also included. This was the first time the Engineer had seriously considered steel fibre concrete on decks, but due to its very restricted corner site the use of mesh would have meant all sort of complications in gaining access to lay.

due to its very restricted


Project Name Express Networks Location Manchester Structural Consultant Marston and Grundy Main Contractor Artisan Ltd. Sub Contractors Metaldeck Ltd., Sidlow Brothers Ltd. Usage Offices/Residential

corner site, steel fibre concrete was the answer


Artisan asked the Engineer to consider the use of Steel Fibre Concrete, as they could see that there were a number of days time saving to be made and after looking at all the evidence and information given by Bekaert, Kingspan and Metaldeck, the engineer made an informed decision to proceed with Dramix Fibre Reinforcement.

Mixed Use

Spurriergate
York
Kingspan and Dramix provided an innovative solution to the parking difficulties and constricted conditions in York City centre. The Spurriergate project comprised retail space on the ground floor and 13 two-bedroom apartments over a further three floors. The area was sited in the busiest shopping location in what is, ostensibly, a medieval city layout.
Project Name Spurriergate Location York Structural Consultant Halcrow Group Ltd Main Contractor Quarmby Sub Contractor Metaldeck Usage Shops/Offices/Single Living

pre-reinforced concrete
Due to the confined nature of the site the engineers and main contractor needed to minimise site traffic and crane lifts. One way to do this was by eliminating the steel mesh used in the composite floor decking. Dramix steel fibres were added to the hopper during mixing to create "pre-reinforced" concrete which meant several lorry loads and crane lifts could be eliminated from the programme. In addition this meant that valuable storage space on site could be freed up for other uses. Using Dramix Steel Fibres in conjunction with Kingspan's Multideck MD60 gave a mesh-free, proven fire-rated solution. The complex fixing and concrete pumping requirements was undertaken by Kingspan approved fixers, Metaldeck of Skelmersdale.

Withington House, Manchester

Education

University of Nottingham
Nottingham
This 11,000,000 scheme comprised of the construction of phase 2 of the Centre for Bio Molecular Sciences research buildings and general academic buildings.

impressed very the ease with of laying the floors


This was the first time that the engineer The Ward Cole Partnership had considered the use of Steel Fibre Concrete on Steel Decks, tight proximity of the new building to existing buildings created access problems which would have been difficult to solve with mesh reinforcement. So they looked very seriously at the Fibre Solution and decided to proceed! Thomas Fish & Son Ltd bought its steel fibre reinforced concrete form Lafarge, who dosed the fibre into their concrete at a local batching plant. Thomas Fish were very impressed with the ease of laying the floors and their Site Manager Ranjit Lall stated that he would certainly consider Steel Fibre Reinforcement on decks on future projects!

Project Name University of Nottingham Location Nottingham Structural Consultant Ward & Cole Partnership Main Contractor Thomas Fish & Sons Ltd Sub Contractors MSW, Northern Flooring Usage University

Education

Bishop Auckland College


County Durham
The 9,500,000 scheme comprised of the comprehensive re-development of the colleges main campus, including the demolition of approximately 8,380 sqm of buildings and the construction of 7,000 sqm of classrooms. Metaldeck made the suggestion of using Steel Fibre Concrete on the decks of this project, and Cundall Johnston made an investigation into the viability and decided that there were definite advantages to the use of fibres over mesh. Tarmac bought and dosed the fibres at their local batching plant for Wyn Construction to pump and place the concrete onto all 3 storeys of the building.

Project Name Bishop Auckland College Location County Durham Engineer Cundall Johnston & Partners Main Contractor Surgo Construction Ltd Sub Contractor Metaldeck Ltd., Wyn Construction Usage College

solution for latest project


All went successfully and Surgo are now considering Fibres as a solution for its latest project, another educational building in the North East of England

Residential

Broad Road Apartments


Sale, Manchester
Project Name Broad Road Apartments Location Sale, Manchester Architect MBLA Architects & Urbanists Main Contractor Richardson Projects Ltd. Sub Contractors Metaldeck Ltd., Technic Concrete Floors Ltd Usage Residential

The 15,000,000 scheme comprises of the erection of 2 apartment blocks (six storeys and seven storeys high) along with 45 2 bedroom apartments, and a multi storey car park to provide 460 spaces on 10 split levels. The site is a corner site with very tight access between the main road and the railway line, giving a very cramped area for services on site. So the use of fibres was considered so as to remove the obvious problems that laying large sheets of mesh reinforcement presented. So Steel Fibre Reinforcement was decided upon for access reasons, but also for time savings, and the Health and Safety issue of removing an obvious trip hazard.

access tight fibre - so reinforced concrete was the perfect solution


Technic Flooring who have worked with Richardson Projects on previous jobs, suggested the use of Fibre concrete at a meeting where access problems with laying the mesh were being discussed. Richardson Projects took this on board and after discussions with the client proceeded with the fibre reinforced concrete.

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Residential

Quebec
Salford
Quebec Buildings in Salford, Greater Manchester is a residential scheme built by property developers, the Vermont Group. The 7 million development comprises 152 apartments together with smaller commercial units. The complex is 6 storeys high and includes a basement car park for residents. Designed by Stephenson Bell Architects the building features zinc metal cladding on the facade. The Structural Consultant, Clancy Consultants selected a composite slab floor to reduce the overall amount of concrete that would be required in the build programme. By specifying Dramix steel fibres the consultant also ensured that the floor construction would be fast-track and not reliant on mesh which is problematic to transport, store, lift and position. Construction Director for Vermont, Mr Mark Colton commented Using steel fibres with a composite deck was a first for the group and it was essential that everything went right on such a large project as this. We were impressed with how the product simplified and speeded up the pouring process. The end result was a smooth floor with less of the hassle involved with mesh. Fire and acoustics are important areas in residential design. The SCIs robust details for composite slab floors provide residential solutions to meet Part E of the Building regulations. In addition the SCI have proven the performance of Kingspan Multideck MD60 and Dramix steel fibres together and endorse the design for 1 and 1.5 hours fire rating.
Project Name Quebec Buildings Location Salford Structural Consultant Clancy Consulting Main Contractor Vermont Group Sub Contractors Metaldeck/CAY Flooring Usage Residential

Havenside, Cambridgeshire

E1.4, Milton Keynes

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Retail

Westwood Cross
Broadstairs, Kent
One of the challenges facing the design team on the 50m contract for the Westwood Cross Shopping Centre, Thanet which opened in June 2005 was the large area of first floor which needed to be constructed with maximum flexibility to suit the future incoming tenants. Alongside this were the needs for ultra fast construction and no applied finishes. The problem of keeping composite floors economically thin whilst providing fire resistance and adequate crack control is normally frustrated by the use of steel mesh reinforcement particularly at the lap positions. All too frequently this leads to the need for increased concrete thickness to prevent the mesh grinning through. The problems were solved by using Kingspan MD60 decking with un-propped spans up to 3.3m infilled with concrete reinforced with Bekaert RC65/60BN steel fibres.
Project Name Westwood Cross Location Thanet, Broadstairs, Kent Structural Consultant Reuby & Stagg Main Contractor Carillion Sub Contractors MSW/OKeefes Usage Retail Park

maximum flexibility and


ultra fast construction
Despite some contractor concern the use of fibres became an unqualified success and fixing of screed rails and stop ends was considerably simplified as was the power floating of the slabs. The success of steel fibre reinforced concrete metal decking led to the ground floor slabs also being constructed using steel fibre. This obviated placement difficulties when working over mesh and provided far more extensive crack control through the full depth of the concrete.

Debenhams, Thanet

Comments by Roger Stagg

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Commercial

Talbot Road
Manchester
The first project for 2004 using Kingspans MD60 and Dramix fibres was a 4 storey office development on Talbot Road in Manchester. The site had very limited access being situated between two existing office blocks and the only site access being onto the small car park area at the front of the building. The decision was made to use Dramix steel fibres instead of mesh mainly because of site access, but also health and safety issues such as reducing mesh handling, and trip hazards during the flooring operation. The steeldeck & fibre concrete solution carries a minimum 1 hour fire rating. Fire load tables were developed by the Steel Construction Institute based on large scale fire testing undertaken at the Warrington Fire Research Establishment.
Project Name Talbot Road Location Manchester Structural Consultant Shaw Whitmore Fyffe Partnership Main Contractor Parkinsons Sub Contractors Metaldeck/Tarmac Topmix Usage Offices

4 floors laid in 2 days

The fibres were batched by conveyor directly into the truck mixers at the Tarmac Topmix Batching plant in Salford. After arriving on site the concrete was pumped directly onto all 4 floors which were laid in 2 days. Despite being on a main road, congestion was kept to a minimum, as pre-reinforced concrete was pumped into place.

IO Business Centre, Glasgow

Sunderland Marine Assurance, Durham

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Kingspan Structural Product Range


Multibeam Technical Handbook
Kingspan Structural Products produce a complete range of pre-engineered cold formed products for modern industrial and commercial building construction.

Multichannel Technical Handbook


The Multichannel range is contained within the Multibeam technical manual.

Multideck Technical Handbook


Multideck is a high performance profiled galvanised steel deck for use in the construction of composite floor slabs. This publication contains complete technical information on the Multideck products produced by Kingspan Structural Products.

Kingspan Toolkit Software


The Toolkit series has become the leading cold rolled steel and floor decking design software in the industry and is now used by structural engineers in over 1000 practices in the UK. The structural design software has been used industry wide to save valuable design time.

Multichannel4 Technical Handbook


Multichannel4 can provide a more efficient and economical alternative to traditional construction materials such as hot rolled steel, timber, masonry and concrete.

Kingspan Metl-Con Limited


Sherburn, Malton, North Yorkshire, YO17 8PQ, England Tel: +44 (0) 1944 712000 Fax: +44 (0) 1944 710555 Email: sales@kingspanmetlcon.co.uk visit our website kingspanstructural.com or our group website kingspan.com
Due to our continuing policy of development and improvement we reserve the right to alter and amend the specification as shown in this literature.